Question 1

How to overhaul the clutch disc on Toyota Corolla?

Accepted Answer

The overhaul procedure for clutch disc begins with manual transaxle assembly disassembly and then the removal of clutch release fork sub-assembly containing clutch release fork and bearing. The clutch release bearing assembly needs to be broken free from the fork to remove the release fork support from the transaxle assembly. The clutch cover assembly can be detached by centering the matchmarks from the flywheel sub-assembly. Loosen one set of bolts at a time to relieve spring tension until you can remove the six bolts and pull away the clutch cover assembly without letting the clutch disc assembly fall. You should remove the clutch disc assembly while maintaining a clear surface on its lining and pressure plate and flywheel to prevent contamination by oil or foreign materials. Vernier calipers must be used to measure the rivet head depth in the clutch disc assembly and diagnose an excessive reading beyond 0.3 mm (0.012 inch). In such a case, the assembly requires immediate replacement. After proper direction insertion of the clutch disc assembly into the transaxle assembly check its runout using a dial indicator to confirm less than 0.8 mm (0.031 inch) deviation. Replace if runout exceeds the limit. Measure the diaphragm spring wear of the clutch cover assembly with vernier calipers to ensure both depth remains below 0.5 mm (0.020 inch) and width remains less than 6.0 mm (0.236 inch). Change the assembly when necessary. Test the flywheel sub-assembly runout by using a dial indicator to verify it is below 0.1 mm (0.004 inch) because replacement is needed if this value is exceeded. Turn the clutch release bearing assembly manually under axial pressure then change the component if needed. Special Service Tool 09301-00210 should be used to install the clutch disc assembly following correct orientation. Position the matchmarks from both the clutch cover assembly and flywheel sub-assembly before tightening the six bolts to 19.1 Nm (195 kgf-cm, 14 ft. lbs.) at specified torque sequence maintaining uniform clamp load and verifying disc position. Check diaphragm spring tip alignment of the clutch cover assembly with a dial indicator. This alignment should not exceed 0.5 mm (0.020 inch) maximum non-alignment but if needed adjust it using Special Service Tool: 09333-00013. To install the release fork support join the transaxle assembly at 36.8 Nm (375 kgf-cm, 27 ft. lbs.) beforeInstalling the release bearing hub clip and clutch release fork sub-assembly with an application of release hub grease (Part No. 08887-01806) to essential contact areas. The installation requires clutch spline grease (Part No. 08887-01706) on the input shaft spline before putting the bearing into the release fork which leads to the transaxle assembly resulting in proper release fork movement. The manual transaxle assembly and clutch release fork boot need installation as the final steps.

Question 2

How to overhaul the clutch disc on Toyota Matrix?

Accepted Answer

The clutch disc overhaul sequence begins with manual transaxle assembly extraction and continues with the removal of the clutch release fork sub-assembly that requires dismantling of the clutch release fork with its clutch release bearing from the transaxle assembly. The next step is to remove the clutch release bearing assembly from the clutch release fork and afterward extract the release fork support from the transaxle assembly together with the release bearing hub clip and the clutch release fork boot. Starting from matchmarks, loosen each set bolt gradually with one turn until spring tension releases so you can remove the 6 bolts that detach the clutch cover assembly to avoid dropping the clutch disc assembly. The technician will separate the clutch disc assembly while also maintaining a clean condition for its lining part along with the pressure plate and flywheel sub-assembly surface. Use vernier calipers to check the depth of clutch disc assembly rivet heads which must be less than 0.3 mm (0.012 inch) for proper operation or replace the assembly. You must install the clutch disc assembly into the transaxle assembly with accurate direction before verifying its runout with a dial indicator until it reaches 0.8 mm (0.031 inch) for necessary replacement. To check diaphragm spring wear within the clutch cover assembly use a vernier caliper then inspect both the depth which must be minimum 0.5 mm (0.020 inch) and the width that needs to measure 6.0 mm (0.236 inch); do a replacement when necessary. A dial indicator should be used to check the flywheel sub-assembly runout to ensure it does not exceed 0.1 mm (0.004 inch) since replacement will be required if this value is exceeded. Testing the clutch release bearing assembly with hand movement under axial force conditions requires a replacement of the assembly if necessary. Use Special Service Tool: 09301-00210 to install the clutch disc assembly before installing it into the flywheel sub-assembly with the correct orientation. Position the clutch cover assembly according to matchmarks before applying torque to 19.1 Nm (195 kgf-cm, 14 ft. lbs.) to the specified 6 bolts in the right sequence while verifying that the disc remains centered. Use a dial indicator to check the diaphragm spring tip alignment in the clutch cover assembly while inspecting the maximum non-alignment distance; this distance should not exceed 0.5 mm (0.020 inch). Adjust the assembly with Special Service Tool: 09333-00013 if necessary. Installation of the release fork support to the transaxle assembly requires torque 36.8 Nm followed by installing the release bearing hub clip and clutch release fork sub-assembly. Release hub grease (Part No. 08887-01806) must be applied to specified contact points before each component gets installed. The clutch spline grease (Part No. 08887-01706) should be applied to the input shaft spline before installing the clutch release bearing assembly. Make sure the release bearing moves easily during installation. Place the clutch release fork boot and the manual transaxle assembly as the last stage of installation.

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